MOD SHACK MOD: Boost improvements for $.16 cents (DV Tuning!).........>>

TTschwing · 06-10-2002, 09:25 AM

One of the things you discover as you add more mods and instrumentation to this car is sometimes things don't work the way you assume they should. Take Boost for instance. Adding the boost gauge gave me a window into how, when and how much boost was developing over a variety of condidtions. I was surprised how much throttle was required to put the car "on boost" and how soon boost dropped out with slight relaxation of the pedal. Hmmm....Maybe time to grease the DV (Forge 006, Green spring, aluminum, piston). Upon dissassembly everything looked fine. Began to think how and why the piston operates. Boost pressure bleed, spring tension and vacume affect whether the piston remains seated (and holds boost) or not (and bleeds boost). I figured increasing the spring tension would keep the valve seated longer. Off to Lowes for some washers (shims). I placed 2 washers (35mmx2.5mm) into the piston for a total of a 5mm shim, inserted the spring and bolted it back together. Guess what?

Boost now comes on with slight throttle tip in, holds longer, and is more linear in it's delivery. Not a bad improvement for 16 cents! One you can feel and see on the Gauge.
Here's the DV with shims (er....washers). Just slip them into the piston, insert spring, and bolt back together.

The washers fit the older Blue plastic piston as well:

Current set-up with APR Chip and FMIC is showing a peak of 18PSI (1.24 BAR) on the gauge. It pulls strongly into redline in every gear with no power drop-offs. All in all, a pretty good boost for the buck...

Steve

More DV stuff here

joe@vwvortex · 06-10-2002, 09:47 AM

for those without a boost gauge.

GoKart3 · 06-10-2002, 09:51 AM

hoTTub · 06-10-2002, 09:52 AM

try that as well.

Do you have the 006 (big)or the 007p(small) ?

Rennen · 06-10-2002, 09:53 AM

Lightweight-USPowah · 06-10-2002, 09:59 AM

Id love to see some data backing up your findings.. Should have never told people about this, you could have took another companys design, changed a thing or 2, add the spacers, call it a day and then market it as your own DV..

When you say power drop offs, are you talking about the boost drop at 6200ish rpms?? Im still running the stock chip and Ive noticed the boost drops off at 6200rpms (about).. It actually starts to increase at about 5800 then peaks, then at 61 or 6200rpms it drops big time..

JustJeff · 06-10-2002, 10:02 AM

I'm off to get these washers, and dis-assemble my Forge.
I'll report back later.

Jason Chen · 06-10-2002, 10:02 AM

Boost spike 1.2-1.3bar
Settles 1 bar
5500-6k+ drops down to almost .6 bar depending on weather.

Lightweight-USPowah · 06-10-2002, 10:04 AM

CJ S4 (aka CJ TT) · 06-10-2002, 10:05 AM

06-10-2002, 09:25 AM	#1
TTschwing AudiWorld Uber User Account #: 13940 Join Date: Dec 2000 Posts: 53,321	MOD SHACK MOD: Boost improvements for $.16 cents (DV Tuning!).........>> One of the things you discover as you add more mods and instrumentation to this car is sometimes things don't work the way you assume they should. Take Boost for instance. Adding the boost gauge gave me a window into how, when and how much boost was developing over a variety of condidtions. I was surprised how much throttle was required to put the car "on boost" and how soon boost dropped out with slight relaxation of the pedal. Hmmm....Maybe time to grease the DV (Forge 006, Green spring, aluminum, piston). Upon dissassembly everything looked fine. Began to think how and why the piston operates. Boost pressure bleed, spring tension and vacume affect whether the piston remains seated (and holds boost) or not (and bleeds boost). I figured increasing the spring tension would keep the valve seated longer. Off to Lowes for some washers (shims). I placed 2 washers (35mmx2.5mm) into the piston for a total of a 5mm shim, inserted the spring and bolted it back together. Guess what? Boost now comes on with slight throttle tip in, holds longer, and is more linear in it's delivery. Not a bad improvement for 16 cents! One you can feel and see on the Gauge. Here's the DV with shims (er....washers). Just slip them into the piston, insert spring, and bolt back together. The washers fit the older Blue plastic piston as well: Current set-up with APR Chip and FMIC is showing a peak of 18PSI (1.24 BAR) on the gauge. It pulls strongly into redline in every gear with no power drop-offs. All in all, a pretty good boost for the buck... Steve More DV stuff here __________________ no sig, Not here

06-10-2002, 09:47 AM	#2
joe@vwvortex Member Account #: 4599 Join Date: Apr 2000 Posts: 13,287	Run a Vag-Com log of Block 115 - it's your boost in mBar - its also a good way to test for those without a boost gauge.

06-10-2002, 09:51 AM	#3
GoKart3 Member Account #: 25185 Join Date: Sep 2001 Posts: 7,066	Hmmmm..... very interesting. __________________ AW.... DIAF.

06-10-2002, 09:52 AM	#4
hoTTub Member Account #: 11019 Join Date: Oct 2000 Posts: 17,304	Steve, isn't the green spring a higher tension? Maybe you should try that as well. Do you have the 006 (big)or the 007p(small) ? __________________

06-10-2002, 09:53 AM	#5
Rennen Elder Member Account #: 8364 Join Date: Aug 2000 Posts: 13,809	Where, exactly, do you place the shims? At the "back" of the spring or on the piston end?

06-10-2002, 09:59 AM	#6
Lightweight-USPowah AudiWorld Super User Account #: 25882 Join Date: Sep 2001 Location: Manhattan, NY Posts: 11,261	Awesome steve.. Could you do some vag testing for the lazy people?` Id love to see some data backing up your findings.. Should have never told people about this, you could have took another companys design, changed a thing or 2, add the spacers, call it a day and then market it as your own DV.. When you say power drop offs, are you talking about the boost drop at 6200ish rpms?? Im still running the stock chip and Ive noticed the boost drops off at 6200rpms (about).. It actually starts to increase at about 5800 then peaks, then at 61 or 6200rpms it drops big time.. __________________ 5.7 Liters of Forced American Muscle: 2 + 8 = 715 6.0 Liters of American AWDrivin Muscle & 599ccs of Japanese Track Samurai (ninja style) http://public.fotki.com/johnjacobjingleheimer/

06-10-2002, 10:02 AM	#7
JustJeff Elder Member Account #: 2847 Join Date: Mar 2000 Posts: 21,786	Wow, after MichaelTT's post ealier regarding his DV, and thoughts that mine might be sticking... I'm off to get these washers, and dis-assemble my Forge. I'll report back later. __________________

06-10-2002, 10:02 AM	#8
Jason Chen AudiWorld Super User Account #: 4297 Join Date: Apr 2000 Posts: 12,097	The drops I get is....... Boost spike 1.2-1.3bar Settles 1 bar 5500-6k+ drops down to almost .6 bar depending on weather. __________________ Sigless

06-10-2002, 10:04 AM	#9
Lightweight-USPowah AudiWorld Super User Account #: 25882 Join Date: Sep 2001 Location: Manhattan, NY Posts: 11,261	wow.. Mine doesn't drop until Im above 6200 rpms .. you have a stock 225? __________________ 5.7 Liters of Forced American Muscle: 2 + 8 = 715 6.0 Liters of American AWDrivin Muscle & 599ccs of Japanese Track Samurai (ninja style) http://public.fotki.com/johnjacobjingleheimer/

06-10-2002, 10:05 AM	#10
CJ S4 (aka CJ TT) New Member Account #: 36009 Join Date: Apr 2002 Posts: 446	Do washers void the warranty? lol

Thread Tools	Search this Thread
Show Printable Version Email this Page	Search this Thread: Advanced Search
Display Modes
Linear Mode Switch to Hybrid Mode Switch to Threaded Mode


Discussion Forums:	Advanced Search